Post on 02-Jun-2020
Bearing and Equipment Lubrication Strategies - Getting it Right.
What is it and Why Do It?
1. What is it & Why Do It?2. Proactive Maintenance.3. Assessments - Getting Started.4. Management. 5. Implementation .6. Lubrication Root Cause Failure Analysis
Today we talk about
Lubrication Reliability
What is it and Why Do It?
➢ Direct effect on reliability!➢ Reduces failures!➢ Reduces wear!➢ Uses less bearings!➢ Reduces lube consumption!➢ Increases business results!
The Impact.
What is it and Why Do It?
➢ The right Lube.➢ The right Time.➢ The right Amount.➢ The right Way.➢ In the right Condition.➢ Kept in the right Condition.
The 6 Lubrication R's
It’s Not Easy!
What is it and Why Do It?
Over 60% of bearing failures are lubrication related.
The Evidence!
What is it and Why Do It?
➢ Over 60% of bearing failures are lubrication related.
Our own Evidence!
➢ 15% were due to poor maintenance issues.
➢ 5% were due to ignorance issues.
➢ 15% The balance (approx) in good condition
Important Consideration
What is it and Why Do It?
Important Considerations
What is it and Why Do It?
Important Considerations
What is it and Why Do It?
Important Considerations
Lubrication Film Thickness.➢ 1/20th of a strand of
hair.
What is it and Why Do It?
Lubrication Reliability Summary
1. Lubrication causes bearing damage
2. Bearings are the machine center
3. Lubrication must work reliably
4. Machine reliability will improve
What is it and Why Do It?
Lubrication ReliabilityPart 2. ProActive Maintenance
We Start with The 6 Lubrication Rights.
ProActive Maintenance
The Right Lube
ProActive Maintenance
The Right Time
ProActive Maintenance
The Right Quantity
ProActive Maintenance
The Right Way
ProActive Maintenance
The Right Condition
ProActive Maintenance
Kept in the Right Condition
ProActive Maintenance
Important Considerations!
ProActive Maintenance
6th R – Maintained in the Right Condition.
➢ Kept Clean➢ Chemically Sound
…. Working Reliably!
Prediction? Strategy? Data Base?
Explaining ProActive Maintenance
ProActive Maintenance
A process of eliminating failures or problems that could be repetitive.
Based on the Deming Model of Plan, Do, Check and Act
Plan, Do, Check and Act.
ProActive Maintenance
Must start with defined standards.
ProActive Maintenance
Lubrication ReliabilityPart 3. Assessments – Getting Started
Fundementals!
Assessments – Getting Started
Questions to answer➢ Will a better strategy help us with our
Reliability?
➢ Where are we compared to Best Practices?
➢ What are we doing Right?
➢ What are we doing Wrong?
➢ How much will it cost?
➢ Who will do it - Our self or via a Contractor.
Will a better strategy help us with our Reliability?
Assessments – Getting Started
Where are we compared to Best Practices?
Assessments – Getting Started
➢ Do you have an oil cleanliness standard?
➢ Do you have KPI's for bearing and Lube consumption?
➢ Do you apply the 6R's concept to each point?
➢ Are you doing RCFA on all damaged parts?
What are we doing Right?
Assessments – Getting Started
What are we doing Wrong?
Assessments – Getting Started
How much will it cost?
Assessments – Getting Started
Strategic Parts!
Assessments – Getting Started
All activities to improve reliability
Processes & tools to reduce equipment wear and damage
The people and their commitment to the work
Administration of the work to be done
Maturity / Development Levels
Assessments – Getting Started
Cleanliness and Contamination
Control
Data Base Management and Reporting
Lubrication Knowledge and
Application
Activity Maturity Level
Basic Requirement
Lubrication Processes
ProactiveLubrication
Management
AssetEfficiencyCulture
Lubrication Strategy
Targets
Assessments – Getting Started
LubricationStrategy
Cleanliness & Contamination
Control
Data Base Management and Reporting
Lubrication Knowledge & Application
DedicatedResources
Lube Room Standards in
Place
Data Base Existence
Cost verses Investment in
Uptime
Instructions for the Work
Procedures for Reducing
Contamination
Maintenance Planning Controls
Trained Staff on Lubrication
RCFA on all failed Parts
Oil Analysis and Evaluation
Dedicated Lube Software
Integrated in Reliability Program
KPI’s on Lube Effect to
Reliability
Overall Plant Cleanliness
Measurements
Integrated and Seamless to
CMMS
Measurement of Activity
Effectiveness
AssetEfficiencyCulture
Basic Requirement
Lubrication Processes
ProactiveLubrication
Management
Assessments – Getting Started
Document your Plan
Assessments – Getting Started
Lubrication ReliabilityPart 4. Management
Overview
Management
Prediction. Oil Analysis and Contamination Control.
Data Base. How we control the activity.
ROI. Return on Investment
Management
Prediction. Oil Analysis and Contamination Control.
Determining when the lubrication is not working reliably.
Contamination Loss of Lube Film Thickness
Oil Analysis Oil Analysis
Vibration
Thermography
Ultra Sonics
Management
Prediction. Oil Analysis and Contamination Control.
Determining when the lubrication is not working reliably.
Testing for:-➢ Viscosity➢ Oxidation➢ Water➢ Solid contaminants➢ Loss of additives
Oil Analysis
Number 1 cause of damage is 3 Body Abrasive Wear
Management
➢ Shown by 3 numbers (22/18/13)
➢ Number of particles of 4, 6, and 14 µm, in 1 ml of oil.
Example = ISO Code 22/18/13
Larger than 4 µm = 22,340
Larger than 6 µm = 1,950
Larger than 14 µm = 43
Management
KPI for Oil Cleanliness = ISO 4406
The Effects Of Filtration
Management
The Dirty Path of Contamination
Oil arrives on siteISO 18/16/13
Oil barrel left openISO 20/18/15 (4x)
Oil dispensed in dirty containerISO 22/20/17 (16x)
Dirty stick used to check level 21/19/16 (8x)
Dirty hoses and funnels usedISO 23/21/18 (32x)
Machine run without protectionISO 24/22/19 (64x)
WEAR AND FAILURE
Management
How Do You Store Your Lubricants Now?
How Do Contaminants Accumulate?
➢ Oil arrives on site. (possible ISO 18/16/13)➢ If a drum is left open.➢ Dirty stick to check the drum level.➢ Oil dispensed with dirty containers.➢ Dirt hoses and funnels used.➢ Machine running without air breathers.➢ Wear debris is being generated in the machine and
oil is not filtered. (possible ISO 24/22/11)
16/14/11
Management
Prevention Mechanisms
Management
Prediction. Oil Analysis and Contamination Control.
Start with Clean Oil
Clean & Safe Dispensing
Ongoing Filtration
Data Base Management
Management
Data Base. How we control the activity.
1. Plant structure ▪ Plant down to specific point.
2. Activity / point▪ Lube, Qty, Process, Freq.
3. Time based Schedules▪ Paper copies or Handheld PC’s
4. Closing out completed schedules
5. Enabling / Disabling points
6. Catering for shut down activities
7. Managing Routes▪ Changing points / responsibilities
8. Reporting activities and consumption
Ease of use
Most CMMS do not go down into enough details to manage the lubrication activity effectively.
Fact!
Management
Data Base. How we control the activity.
Stand AloneVender Specific
Internet BasedVender Neutral
Internet BasedVender Specific
Stand Alone Vender Neutral
Management
ROI. Return on Investment
Management
ROI. Return on Investment
Improvements in Cleanliness of Diesel Engines
From 19/16 ISO code to 15/12 gave a 3 X Life Extension.
Mean Time Between Engine Rebuilds, from 7,200 hours to 21,000 Hours.
➢ 5 Year Net Gain = $ 702,391.00
➢ Rate of Return = 662%➢ Payback Period = 2.04 m
Port of Tacoma Case Study
Lubrication ReliabilityPart 5. Implementation
Implementation Plan
Key Activities
1. Define the lubes and create a colour coded system.2. Establish and fill a Data Base.3. Set KPI’s for the lubrication activity.4. Create a clean and dry Lube storage facility.5. Create a labelling system for storage, dispensing and the machines.6. Initiate an Oil Analysis program to control the KPI’s.7. Train the key lubrication staff on all facets of lubrication. 8. Fit desiccant breathers to all key oil systems.9. Establish a filtering system to keep the oil clean.
Implementation Plan
1. Add the right Lube in the right machine?2. Add it at the right time.3. Add the right amount of lube.4. Done in the right way.5. With it in the right condition.6. And kept in the right condition.
We ask ourselves In all planning activities. “Will this action ensure that we will always…..”
The Continual Check List!
Implementation Plan
Define the lubes and create a colour coded system.
Implementation Plan
Establish and fill a Data Base. Start with Key component standards
Implementation Plan
Establish and fill a Data Base.Key Information.
Building IDRoute IDPoint IDLube ID and colourFrequency Of lubricationQuantity of lube to be added
Lubrication Schedule
Special InstructionHow to lubeCleaning
Oil AnalysisInspection Filtering
Implementation Plan
Create a clean and dry Lube storage facility.
Implementation Plan
Set KPI’s for the lubrication activity.
➢ Oil Cleanliness levels per application.➢ Lubrication Consumption➢ Bearing Consumption.➢ 100% of achieved schedule.➢ 100% of RCFA on damages.
Implementation Plan
Create a labelling system for storage, dispensing and the machines.
Implementation Plan
Initiate an Oil Analysis program to control the KPI’s.
Implementation Plan
Train the key lubrication staff on all facets of lubrication.
Implementation Plan
Fit desiccant breathers to all key oil systems. .
Implementation Plan
Establish a filtering system to keep the oil clean.
Implementation Plan
.Train the staff on bearing Failure analysis.
Implementation Plan
And finally to be innovative